Research On Standard Sample Design Of NC Machining And Energy Consumption Data Management System

With the recent increase in energy demand and energy prices, sustainabledevelopment has become a priority for manufacturing industry. From sustainablemanufacturing point of view, most of studies build the cutting energy consumptionmodels to explain the mechanism of machining processes based on the energy datacollection of the designed experimental sample. However, these models and energy dataare difficult to use because of the different design of the standard sample. In this paper,the standard sample was designed for the purpose of energy data analysis and energylabelling of machine tools and products. In addition, the energy data managementsystem was developed to manage energy data of the designed standard sample formachining processes. The main contents of this paper are as follows:Firstly, the applicable standard sample for sustainable manufacturing wasdesigned.The size of the standard sample is suitable for a variety of CNC machiningcenters for machining processes. Commonly used machining features namely facemilling, pocket milling, drilling etc. are considered in the design of the standard sample.Machining features and material removal rate are feasible and reasonable, which makesenergy analysis even simpler to obtain the reliable energy data. The standard sample isalso designed in different materials and the deformtion of the relatively soft materials inthe cutting process is considered.Secondly, in order to optimize the process parameters, each machining feature wasmaching according to the orthogonal experimental design to obtain the optimal solutionand energy data. Finish machining experiment was also performed to obtain the relativeenergy data.Thirdly, the experiments of the standard sample were performed in Haas VF-2vertical machining center to collect energy data. Based on the analysis of variance andmean value method, the experimental data were processed to obtain the optimalcombination and energy data of each machining feature.Finally, the JSP database was developed to manage the energy data of the standardsample we designed. The web-based energy data management system was developedbased on JAVA and Microsoft SQL server2005database. The energy data of standardsample can be used to support the research of sustainable manufacturing.